Method for manufacturing electrolytic capacitor with electrically conductive solid layer and electrolytic capacitor with electrically conductive solid layer

Abstract

A method for manufacturing an electrolytic capacitor including: forming a capacitor element having an anode foil and a cathode foil; impregnating the capacitor element with a dispersion solution containing particles of an electrically conductive solid or aggregates thereof and a dispersion solvent to form an electrically conductive solid layer having the particles of the electrically conductive solid or the aggregates thereof in the capacitor element ; and impregnating the capacitor element having the electrically conductive solid layer with a solvent containing no supporting salt.

What is claimed is: 
     
       1. A method for manufacturing an electrolytic capacitor comprising:
 forming a capacitor element having an anode foil and a cathode foil; 
 impregnating the capacitor element with a dispersion solution containing particles of an electrically conductive polymer or aggregates thereof and a dispersion solvent to form an electrically conductive polymer layer having the particles of the electrically conductive polymer or the aggregates thereof in the capacitor element, 
 wherein the dispersion solution does not contain an unreacted monomer and an oxidizing agent; and 
 impregnating the capacitor element having the electrically conductive polymer layer with a solvent containing no supporting salt or acid acting as an electrolyte, wherein 
 the solvent contains at least one selected from the group consisting of γ-butyrolactone, sulfolane, ethylene carbonate, propylene carbonate, dimethyl carbonate, ethyl methyl carbonate, acetonitrile, propionitrile, dimethyl formamide, and diethyl formamide. 
 
     
     
       2. The method for manufacturing an electrolytic capacitor according to  claim 1 , wherein the electrically conductive polymer contains at least one selected from the group consisting of polythiophene and a derivative thereof. 
     
     
       3. The method for manufacturing an electrolytic capacitor according to  claim 1 , wherein the solvent contains at least one selected from the group consisting of y-butyrolactone and sulfolane. 
     
     
       4. An electrolytic capacitor comprising:
 a capacitor element having an anode foil and a cathode foil; and 
 an electrically conductive polymer layer containing particles of an electrically conductive polymer or agglomerates thereof and a solvent containing no supporting salt or acid acting as an electrolyte in the capacitor element, 
 wherein the electrically conductive polymer layer is formed by impregnating the capacitor element with a dispersion solution containing the particles of the electrically conductive polymer or agglomerates thereof and a dispersion solvent, 
 wherein the dispersion solution does not contain an unreacted monomer and an oxidizing agent, 
 wherein the solvent contains at least one selected from the group consisting of γ-butyrolactone, sulfolane, ethylene carbonate, propylene carbonate, dimethyl carbonate, ethyl methyl carbonate, acetonitrile, propionitrile, dimethyl formamide, and diethyl formamide. 
 
     
     
       5. The electrolytic capacitor according to  claim 4 , wherein the electrically conductive polymer contains at least one selected from the group consisting of polythiophene and a derivative thereof. 
     
     
       6. The electrolytic capacitor according to  claim 4 , wherein the solvent contains at least one selected from the group consisting of γ-butyrolactone and sulfolane. 
     
     
       7. A method for manufacturing an electrolytic capacitor comprising:
 forming a capacitor element having an anode foil and a cathode foil; 
 impregnating the capacitor element with a dispersion solution containing particles of an electrically conductive polymer or aggregates thereof and a dispersion solvent to form an electrically conductive polymer layer having the particles of the electrically conductive polymer or the aggregates thereof in the capacitor element, 
 wherein the dispersion solution does not contain an unreacted monomer and an oxidizing agent; and 
 impregnating the capacitor element having the electrically conductive polymer layer with a solvent not acting as an electrolytic solution, wherein 
 the solvent contains at least one selected from the group consisting of γ-butyrolactone, sulfolane, ethylene carbonate, propylene carbonate, dimethyl carbonate, ethyl methyl carbonate, acetonitrile, propionitrile, dimethyl formamide, and diethyl formamide. 
 
     
     
       8. The method for manufacturing an electrolytic capacitor according to  claim 7 , wherein the electrically conductive polymer contains at least one selected from the group consisting of polythiophene and a derivative thereof. 
     
     
       9. The method for manufacturing an electrolytic capacitor according to  claim 7 , wherein the solvent contains at least one selected from the group consisting of γ-butyrolactone and sulfolane. 
     
     
       10. An electrolytic capacitor comprising:
 a capacitor element having an anode foil and a cathode foil; and 
 an electrically conductive polymer layer containing particles of an electrically conductive polymer or agglomerates thereof and a solvent not acting as an electrolytic solution in the capacitor element, 
 wherein the electrically conductive polymer layer is formed by impregnating the capacitor element with a dispersion solution containing the particles of the electrically conductive polymer or agglomerates thereof and a dispersion solvent or acid acting as an electrolyte, 
 wherein the dispersion solution does not contain an unreacted monomer and an oxidizing agent, wherein the solvent contains at least one selected from the group consisting of γ-butyrolactone, sulfolane, ethylene carbonate, propylene carbonate, dimethyl carbonate, ethyl methyl carbonate, acetonitrile, propionitrile, dimethyl formamide, and diethyl formamide. 
 
     
     
       11. The electrolytic capacitor according to  claim 10 ,
 wherein the electrically conductive polymer contains at least one selected from the group consisting of polythiophene and a derivative thereof. 
 
     
     
       12. The electrolytic capacitor according to  claim 10 ,
 wherein the solvent contains at least one selected from the group consisting of γ-butyrolactone and sulfolane. 
 
     
     
       13. A method for manufacturing an electrolytic capacitor comprising:
 forming a capacitor element having an anode foil and a cathode foil; 
 impregnating the capacitor element with a dispersion solution containing particles of an electrically conductive polymer or aggregates thereof and a dispersion solvent to form an electrically conductive polymer layer having the particles of the electrically conductive polymer or the aggregates thereof in the capacitor element, 
 wherein the dispersion solution does not contain an unreacted monomer and an oxidizing agent; and 
 impregnating the capacitor element having the electrically conductive polymer layer with a solvent containing no supporting salt or acid acting as an electrolyte. 
 
     
     
       14. The method for manufacturing an electrolytic capacitor according to  claim 13 , wherein the electrically conductive polymer contains at least one selected from the group consisting of polythiophene and a derivative thereof. 
     
     
       15. An electrolytic capacitor comprising:
 a capacitor element having an anode foil and a cathode foil; and 
 an electrically conductive polymer layer containing particles of an electrically conductive polymer or agglomerates thereof and a solvent containing no supporting salt or acting as an electrolyte in the capacitor element, 
 wherein the electrically conductive polymer layer is formed by impregnating the capacitor element with a dispersion solution containing the particles of the electrically conductive polymer or agglomerates thereof and a dispersion solvent, 
 wherein the dispersion solution does not contain an unreacted monomer and an oxidizing agent. 
 
     
     
       16. The method for manufacturing an electrolytic capacitor according to  claim 15 , wherein the electrically conductive polymer contains at least one selected from the group consisting of polythiophene and a derivative thereof. 
     
     
       17. A method for manufacturing an electrolytic capacitor comprising:
 forming a capacitor element having an anode foil and a cathode foil; 
 impregnating the capacitor element with a dispersion solution containing particles of an electrically conductive polymer or aggregates thereof and a dispersion solvent to form an electrically conductive polymer layer having the particles of the electrically conductive polymer or the aggregates thereof in the capacitor element, 
 wherein the dispersion solution does not contain an unreacted monomer and an oxidizing agent; and 
 impregnating the capacitor element having the electrically conductive polymer layer with a solvent not acting as an electrolytic solution. 
 
     
     
       18. The method for manufacturing an electrolytic capacitor according to  claim 17 , wherein the electrically conductive polymer contains at least one selected from the group consisting of polytheiophene and a derivative thereof. 
     
     
       19. An electrolytic capacitor comprising:
 a capacitor element having an anode foil and a cathode foil; and 
 an electrically conductive polymer layer containing particles of an electrically conductive polymer or agglomerates thereof and a solvent not acting as an electrolytic solution in the capacitor element, 
 wherein the electrically conductive polymer is formed by impregnating the capacitor element with a dispersion solution containing the particles of the electrically conductive polymer or agglomerates thereof and a dispersion solvent, 
 wherein the dispersion solution does not contain an unreacted monomer and an oxidizing agent. 
 
     
     
       20. The method for manufacturing an electrolytic capacitor according to  claim 19 , wherein the electrically conductive polymer contains at least one selected from the group consisting of polythiophene and a derivative thereof.